Pre-filled active vial having integral plunger assembly

ABSTRACT

A pre-filled vial assembly adapted for dispensing and delivering a fluid includes: a body member having a distal end, a proximal end, and a sidewall extending therebetween defining an interior; and a transitionable stopper disposed within the interior of the body member. At least a portion of the body member is engageable with a source of air or fluid for advancing the transitionable stopper from an initial position to an activated position in which at least a portion of a fluid contained within the interior of the body member is advanced therefrom.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/235,836 entitled “Pre-Filled Active Vial Having IntegralPlunger Assembly” filed Aug. 21, 2009, the entire disclosure of which ishereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a pre-filled vial assembly adaptedfor dispensing and delivery of a fluid. More particularly, the presentinvention is directed to a pre-filled active vial having an integralplunger assembly for delivering a fluid that may be directly attached toa standard hypodermic syringe. A regulator for regulating the release ofair from the pre-filled vial assembly is also disclosed.

2. Description of Related Art

Syringe assemblies, and in particular hypodermic syringes, are wellknown in the medical field for dispensing fluids, such as medication. Aconventional syringe typically includes a syringe barrel with an openingat one end and a plunger mechanism disposed through the other end. Theplunger typically includes a plunger rod extending through the barrel,with a plunger head or stopper at the end of the plunger rod within thebarrel and with a finger flange at the other end of the plunger rodextending out of the barrel. In use, the plunger rod is retractedthrough the syringe barrel to fill the syringe barrel with a fluid, suchas a medication, with the plunger rod extending out from the rear end ofthe syringe barrel. For delivery of the medication to a patient, theopening of the syringe barrel is adapted for fluid communication with apatient, such as through a hypodermic needle fitted at the front end ofthe syringe barrel or through a luer-type fitting extending from thefront end of the syringe barrel for attachment with a fluid line of apatient. Upon depressing of the plunger rod, the plunger rod and stoppertravel through the syringe barrel, thereby forcing the contents of thesyringe out through the opening at the front end for delivery to thepatient. Such an operation is well known in the medical field, andmedical practitioners have become well accustomed to the use of suchcommon fluid delivery procedures through standard syringes.

Conventional syringes are well known to be used in connection with avial of a medication, where the user draws the fluid into the syringeimmediately prior to injection and delivery of the fluid to the patient.Oftentimes, hypodermic syringes may be packaged as “pre-filled” devices,wherein the syringe is pre-filled with medication prior to beingpackaged and delivered to the end user. In this manner, there is no needfor the user to fill the device prior to injection, thereby saving timefor the end user and maintaining consistent volumes for delivery.

Pre-filled syringes and pre-filled metered dose syringes are oftenfilled with narcotics or other drugs at a production facility, packaged,and then shipped to a medical facility. Once at the facility, thesesyringes are often placed in controlled storage and/or locked cabinetsto reduce theft of the syringes themselves and/or theft of the contentsof these syringes. The space within these controlled storage locationsis often limited, thus there is a need for a syringe assembly that has asmaller packaging footprint, to reduce the storage space required forcontaining this syringe.

For some applications, small vials and ampoules are used to storemedications and other narcotics or controlled substances. These vialsand ampoules are typically storage vessels and do not typically includea plunger rod or stopper. During use, a medical practitioner draws themedication or controlled substance from the vial or ampoule by insertingthe needle of a standard syringe therein and withdrawing the contents.The process of transferring the contents of a vial or ampoule into asyringe for injection increases the likelihood of contamination. Inaddition, as the majority of ampoules are glass, the transfer processincreases the likelihood that shards of glass may become incorporatedinto the injected fluid.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the present invention, a pre-filledvial assembly adapted for dispensing and delivering a fluid includes: abody member having a distal end, a proximal end, and a sidewallextending therebetween defining an interior; and a transitionablestopper disposed within the interior of the body member. At least aportion of the body member is engageable with a source of air or fluidfor advancing the transitionable stopper from an initial position to anactivated position in which at least a portion of a fluid containedwithin the interior of the body member is advanced therefrom.

The proximal end of the body member may include a receiving cavity. Thepre-filled vial assembly may further include a luer connection having aforward end configured for engagement with the receiving cavity of theproximal end of the body member. The forward end of the luer connectionmay include a seal for internal sealing against a portion of thereceiving cavity. At least a portion of the proximal end of the bodymember may include a sealing member for receipt within a portion of theluer connection.

The luer connection may include a vent. The source of air or gas may beengaged with a fluid passage formed in the luer connection. The sourceof air or gas may be a standard syringe, such that depression of aplunger rod of the standard syringe transitions the transitionablestopper from the initial position to the activated position to expelcontents from the interior of the body member of the pre-filled vialassembly.

The distal end of the body member may include a dispensing tip having afluid passage therethrough in communication with the interior of thebody member. A dispensing cannula may be configured for engagement withthe dispensing tip of the body member. The body member may includemarkings provided on a portion thereof for providing an indication of anamount of fluid that has been expelled during use.

In accordance with another embodiment of the present invention, apre-filled pod assembly includes: a pre-filled pod having a distal end,a proximal end, and a sidewall extending therebetween defining aninterior; a transitionable stopper disposed within the interior of thepre-filled pod; and a regulator coupled to the proximal end of thepre-filled pod and provided in fluid communication with the interior ofthe pre-filled pod. At least a portion of the regulator is engageablewith a source of air or fluid for advancing the transitionable stopperfrom an initial position to an activated position in which at least aportion of a fluid contained within the interior of the pre-filled podis advanced therefrom.

The regulator may be configured to apply a predetermined amount ofpressurized air to the transitionable stopper through the use of a valvedevice. The source of air or gas may be engaged with an access portformed in the regulator. The source of air or gas may be a standardsyringe, such that depression of a plunger rod of the standard syringepressurizes the regulator. The regulator may further include anindicator that is activated to indicate that the regulator has apredetermined amount of pressurized air that is sufficient to deliver acomplete dose. The regulator may include an activation triggerconfigured to be aligned with an indicator for allowing a user to setthe regulator to deliver a metered dose.

In accordance with yet another embodiment of the present invention, apre-filled pod assembly includes: a pre-filled pod having a distal end,a proximal end, and a sidewall extending therebetween defining aninterior; and a capsule having a fluid contained therein and disposedwithin the interior of the pre-filled pod. The capsule includes a firstopening adjacent a first end of the capsule and aligned with theproximal end of the pre-filled pod, and a second opening adjacent asecond end of the capsule and aligned with the distal end of thepre-filled pod. The pre-filled pod assembly also includes atransitionable stopper disposed within the interior of the pre-filledpod between the proximal end of the pre-filled pod and the first end ofthe capsule. At least a portion of the pre-filled pod is engageable witha source of air or fluid for advancing the transitionable stopper suchthat air disposed between the capsule and the transitionable stopper ispressurized and enters the capsule via the first opening, therebyexpelling at least a portion of the fluid from within the capsulethrough the second opening.

At least a portion of the transitionable stopper may seal the firstopening after the transitionable stopper has advanced completely. Avolume of the fluid within the capsule may be greater than a volume ofair disposed between the capsule and the transitionable stopper, whichlimits expulsion of the air from the capsule of the pre-filled pod. Thecapsule may be held within the interior of the pre-filled pod in aspecific orientation by at least one grommet. In addition, an air bubblemay be provided adjacent to the second opening of the capsule to limitexpulsion of the fluid within the capsule absent advancement of thetransitionable stopper.

In accordance with still another embodiment of the present invention, apre-filled pod assembly includes: a pre-filled pod having a distal end,a proximal end, and a sidewall extending therebetween defining aninterior; and a capsule having a fluid contained therein and disposedwithin the interior of the pre-filled pod. The capsule includes a firstopening adjacent a first end of the capsule and aligned with theproximal end of the pre-filled pod, and a second opening adjacent asecond end of the capsule and aligned with the distal end of thepre-filled pod. The pre-filled pod assembly also includes: atransitionable stopper disposed within the interior of the pre-filledpod between the proximal end of the pre-filled pod and the first end ofthe capsule, and a regulator coupled to the proximal end of thepre-filled pod and provided in fluid communication with the interior ofthe pre-filled pod. The regulator is engageable with a source of air orfluid for advancing the transitionable stopper such that air disposedbetween the capsule and the transitionable stopper is pressurized andenters the capsule via the first opening, thereby expelling at least aportion of the fluid from within the capsule through the second opening.

At least a portion of the transitionable stopper may seal the firstopening after the transitionable stopper has advanced completely. Avolume of the fluid within the capsule may be greater than a volume ofair disposed between the capsule and the transitionable stopper, whichlimits expulsion of the air from the capsule of the pre-filled pod. Thecapsule may be held within the interior of the pre-filled pod in aspecific orientation by at least one grommet.

The regulator may be configured to apply a predetermined amount ofpressurized air to the transitionable stopper through the use of a valvedevice. The source of air or gas may be engaged with an access portformed in the regulator. The source of air or gas may be a standardsyringe, such that depression of a plunger rod of the standard syringepressurizes the regulator. The regulator may further include anindicator that is activated to indicate that the regulator has apredetermined amount of pressurized air that is sufficient to deliver acomplete dose. The regulator may include an activation triggerconfigured to be aligned with an indicator for allowing a user to setthe regulator to deliver a metered dose.

These and other features and characteristics of the present invention,as well as the methods of operation and functions of the relatedelements of structures and the combination of parts and economies ofmanufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention. As usedin the specification and the claims, the singular form of “a”, “an”, and“the” include plural referents unless the context clearly dictatesotherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic partial cross-sectional side view of a pre-filledpod assembly and a female luer connector in accordance with anembodiment of the present invention.

FIG. 2 is a schematic partial cross-sectional side view of thepre-filled pod assembly joined with the female luer connector of FIG. 1in accordance with an embodiment of the present invention.

FIG. 3 is a schematic partial cross-sectional side view of thepre-filled pod assembly and female luer connector of FIG. 2 engageablewith a standard syringe in accordance with an embodiment of the presentinvention.

FIG. 4 is a schematic partial cross-sectional side view of thepre-filled pod assembly and female luer connector of FIG. 2 engaged withthe standard syringe of FIG. 3 in an initial position in accordance withan embodiment of the present invention.

FIG. 5 is a schematic partial cross-sectional side view of thepre-filled pod assembly and female luer connector engaged with thestandard syringe of FIG. 4 in an activated position having the contentsof the pod assembly partially expelled therefrom in accordance with anembodiment of the present invention.

FIG. 6 is a schematic partial cross-sectional side view of a pre-filledpod having an alternative female luer connector in accordance with anembodiment of the present invention.

FIG. 7 is a schematic partial cross-sectional side view of thepre-filled pod assembly joined with the female luer connector of FIG. 6in accordance with an embodiment of the present invention.

FIG. 8 is a schematic partial cross-sectional side view of thepre-filled pod assembly and female luer connector of FIG. 7 engaged witha standard syringe in accordance with an embodiment of the presentinvention.

FIG. 9 is a side view of a pre-filled pod assembly and female luerconnector engaged with a standard syringe in an initial position inaccordance with an embodiment of the present invention.

FIG. 10 is a side view of the pre-filled pod assembly and female luerconnector engaged with a standard syringe of FIG. 9 in an activatedposition in accordance with an embodiment of the present invention.

FIG. 11 is a perspective view of a pre-filled pod engaged with aregulator in accordance with an embodiment of the present invention.

FIG. 12 is a perspective view of the pre-filled pod and regulator ofFIG. 11 engaged with a standard syringe in an initial position inaccordance with an embodiment of the present invention.

FIG. 13 is a perspective view of the pre-filled pod and regulatorengaged with a standard syringe of FIG. 12 in the activated position ina first cycle in accordance with an embodiment of the present invention.

FIG. 14 is a perspective view of the pre-filled pod and regulatorengaged with a standard syringe of FIG. 12 in the initial position in asecond cycle in accordance with an embodiment of the present invention.

FIG. 15 is a perspective view of the pre-filled pod and regulatorengaged with a standard syringe of FIG. 12 in the activated position ina second cycle in accordance with an embodiment of the presentinvention.

FIG. 16 is a perspective view of the pre-filled pod and regulator in aninitial position having the “off” speed selected in accordance with anembodiment of the present invention.

FIG. 17 is a perspective view of the pre-filled pod and regulator ofFIG. 16 in an initial position having a specified speed selected inaccordance with an embodiment of the present invention.

FIG. 18 is a perspective view of the pre-filled pod and regulator ofFIG. 16 in an activated position having a specified speed selected inaccordance with an embodiment of the present invention.

FIG. 19 is a cross-sectional front view of a pre-filled pod andregulator engaged with a standard syringe and a dispensing assembly inan initial position in accordance with an embodiment of the presentinvention.

FIG. 20 is a cross-sectional front view of the regulator of FIG. 19 inaccordance with an embodiment of the present invention.

FIG. 21 is a cross-sectional front view of a pre-filled pod andregulator engaged with a standard syringe and a dispensing assembly ofFIG. 19 in an activated position in accordance with an embodiment of thepresent invention.

FIG. 22 is a cross-sectional front view of the regulator of FIG. 21 inaccordance with an embodiment of the present invention.

FIG. 23 is a cross-sectional front view of a pre-filled pod andregulator having an interior glass capsule in an initial position inaccordance with an embodiment of the present invention.

FIG. 24 is a cross-sectional front view of a pre-filled pod andregulator having an interior glass capsule in an activated position inaccordance with an embodiment of the present invention.

DETAILED DESCRIPTION

For purposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”,“longitudinal”, and derivatives thereof shall relate to the invention asit is oriented in the drawing figures. However, it is to be understoodthat the invention may assume various alternative variations, exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices illustrated in the attached drawings, anddescribed in the following specification, are simply exemplaryembodiments of the invention. Hence, specific dimensions and otherphysical characteristics related to the embodiments disclosed herein arenot to be considered as limiting.

Reference is now made to FIGS. 1-5, which depict a pre-filled podassembly 10 which is adapted for dispensing and delivery of a fluid. Thepre-filled pod assembly 10 includes a pre-filled pod 12 and a femaleluer connection 14 adapted for engagement with a portion of thepre-filled pod 12. The pre-filled pod 12 has a distal end 16 and aproximal end 18 and a sidewall 20 extending therebetween defining aninterior 22. The pre-filled pod 12 also includes a transitionablestopper 24 disposed at least partially within the interior 22 of thepre-filled pod 12. The transitionable stopper 24 is dimensioned forinterference fit within the interior 22 of the pre-filled pod 12 tocreate a substantially liquid impermeable seal against the interior ofthe sidewall 20. In one embodiment, the transitionable stopper 24 may bea polymeric material, rubber composition, hard plastic composition, andthe like.

In one embodiment, the pre-filled pod 12 is adapted for containing asubstance 13 therein, such as a fluid medication, sterile water, saline,fluid narcotic, or other controlled substance. The interior 22 of thepre-filled pod 12 may have any suitable storage volume for housing asubstance therein, such as 2-3 ml. It is noted that the storage volumemay be exclusive of the volume occupied by the transitionable stopper24. In one embodiment, the transitionable stopper 24 has a distal end 26and a proximal end 27, with the suitable storage volume defined betweenthe interior 22 of the sidewall 20 of the pre-filled pod 12 and thedistal end 26 of the transitionable stopper 24. In this configuration,the transitionable stopper 24 may be made of a substantiallynon-reactive material so as not to interfere or interact with thesubstance 13 disposed within the pre-filled pod 12. Alternatively, anon-reactive coating and/or non-reactive seal member (not shown) may bedisposed adjacent the distal end 26 of the transitionable stopper 24 toprovide additional sealing between the transitionable stopper 24 and thecontents of the pre-filled pod 12. The sidewall 20 of the pre-filled pod12 may also be made of a substantially non-reactive material, such asglass, one or more polymeric material, and/or a polymeric materialmolded over glass and may optionally be coated with a barrier or othernon-reactive coating.

The distal end 16 of the pre-filled pod 12 may include a dispensing tip28 having a fluid passage 30 therethrough in communication with theinterior 22 of the pre-filled pod 12. When suitable pressure is appliedto the substance 13 of the interior 22 of the pre-filled pod 12, atleast a portion of the substance 13 may pass through the fluid passage30 for expulsion from the pre-filled pod 12, as will be describedherein. The dispensing tip 28 may also include a removable cap 32 forsealing the fluid passage 30.

The proximal end 18 of the pre-filled pod 12 may include a receivingcavity 34 adapted for engagement with a female luer connection 14. Inone configuration, at least a portion of the female luer connection 14is adapted for receipt within the receiving cavity 34. A forward end 40of the female luer connection 14 may include a seal 42, such as an“O-ring”, for internal sealing against a portion of the receiving cavity34. Optionally, a portion of the proximal end 18 of the pre-filled pod12 may also include a sealing member 36 for receipt within a portion ofthe female luer connection 14, as shown in FIG. 2. The female luerconnection 14 includes a fluid passage 44 therethrough, such that fluid,either in the form of a gas or liquid, may pass through the fluidpassage 44 and contact the proximal end 27 of the transitionable stopper24. Engagement of the female luer connection 14 and the pre-filled pod12 may be accomplished by applying a force in the direction of thearrows A shown in FIGS. 1-2. It is noted that in certain configurations,the engagement of the female luer connection 14 with the pre-filled pod12 occurs after aseptic fill and terminal sterilization of thepre-filled pod 12 and indwelling substance 13. As shown in FIG. 2, acaptive air chamber 48 may be formed between the female luer connection14 and the proximal end 27 of the transitionable stopper 24. Thiscaptive air chamber 48 may be open to the atmosphere. Optionally, a diskmember 50, such as a metalized disk, may be provided adjacent theproximal end 27 of the transitionable stopper 24 to assist in barrierand/or structural integrity of the transitionable stopper 24.

As shown in FIGS. 3-5, a source of air or gas, such as a standardsyringe assembly 60, may be engaged with the female luer connection 14.The standard syringe assembly 60 may include a syringe barrel 62 definedby barrel wall 64 extending between a forward or distal end 66 and arearward or proximal end 68, thereby defining interior chamber 70 ofsyringe barrel 62. Syringe barrel 62 may be in the general form of anelongated cylindrical barrel as is known in the art for the generalshape of a hypodermic syringe. Forward end 66 of syringe barrel 62includes an outlet opening 72 which is provided in fluid communicationwith the fluid passage 44 of the luer connection 14, such that onceengaged, the interior chamber 70 of the syringe barrel 62 is provided influid communication with the fluid passage 44 of the luer connection 14.As used herein, the term “fluid” is intended to include both gases andliquids.

The syringe barrel 62 may include markings, such as graduations on thewall thereof, for providing an indication as to the level or amount offluid contained within syringe barrel 62. Such markings may be providedon the external wall, the internal wall, or integrally formed orotherwise within the wall of syringe barrel 62. The syringe barrel 62may further include a finger grasping surface, such as finger flanges 74for providing finger support surfaces for a user during use of syringeassembly 60. The syringe assembly 60 further includes a plunger assembly76, a portion of which is disposed at least partially within syringebarrel 62. Plunger assembly 76 provides a mechanism for dispensing fluidcontained within the interior chamber 70 of syringe barrel 62. Inparticular, plunger assembly 76 includes a plunger rod 78 connected to aplunger head 80 adapted for expelling contents of the interior chamber70 when the plunger rod is pushed in the direction of arrow B, as shownin FIG. 5.

A dispensing cannula 82, such as a patient needle or IV system needle,may be adapted for engagement with the distal end 16 of the pre-filledpod 12, such as the dispensing tip 28. As shown in FIG. 5, when theplunger rod 78 is deployed in the direction of arrow B, fluid,preferably air, is expelled from the interior chamber 70 of the syringebarrel 62 and directed through the fluid passage 44 of the luerconnection 14. The fluid exiting the interior chamber 70 is pressurizedby the action of the plunger rod 78 and contacts the proximal end 27 ofthe transitionable stopper 24 with sufficient pressure to advance thetransitionable stopper 24 from an initial position, as shown in FIG. 4,to an activated position, shown in FIG. 5 in which the substance 13 ofthe pre-filled pod 12 is expelled from the pre-filled pod. It is notedthat the syringe assembly 60 does not directly contact any of thesubstance 13 contained within the pre-filled pod 12 and thus, after useof the pre-filled pod 12, the syringe assembly 60 may be re-used. It isalso noted that the interior chamber 70 of the syringe assembly 60 mayutilize either a gas or a liquid, or both, to advance the transitionablestopper 24. In another configuration, a vent (not shown) may be providedin the proximal end 18 of the pre-filled pod 12 to allow injection of aliquid into the captive air chamber 48 to allow the attachment of astandard syringe assembly 60 and subsequent drug delivery pump (also notshown) for metered dosing.

An advantage of using a pre-filled pod 12 of the present invention isthe small storage space of the pre-filled pod. For example, a largedisadvantage of a pre-filled syringe with a vaccine is that mostvaccines need to be kept in cold storage during transport and prior touse. The small size of the pre-filled pods of the present inventionallows pre-filling with a pre-loaded dose of vaccine that may be easilykept in cold storage. Most institutions have limited space of coldstorage and this design facilitates low storage space. Accordingly, whenthe pre-filled pods are used for pre-filling for “developing countries”in support of vaccination campaigns, the reduced size of the device forcold storage transport, and the lack of a plunger rod being attached tothe stopper, makes the device less desirable for improper re-use of acontaminated product.

Additional advantages of the present invention are a reduction in thenumber of components required to complete a dispensing of a substance,and that a medical practitioner cannot draw the transitionable stopper24 toward the proximal end of the pre-filled pod. It is also notedherein that the dispensing cannula 82 and the female luer connection 14may be appropriately adapted for engagement with any standard systemconventionally known. For example, many pharmaceutical preparations aremanufactured using syringe filling equipment along with nest fillingequipment where the syringes are supplied in a nest holder to thepharmaceutical manufacturer. The active vial design of the presentinvention with the included flange on the open end and standard stopperdesign facilitates the use of existing syringe filling equipment.

Referring to FIGS. 6-8, an alternative connection between the proximalend 18A of the pre-filled pod 12A and the female luer connection 14A isshown. In this configuration, the female luer connection 14A may bedimensioned to at least partially recess into the proximal end 18A ofthe pre-filled pod 12A to further reduce the overall operatingdimensions of the pre-filled pod assembly 10A. As shown in FIG. 8, thesyringe assembly 60A may also be at least partially recessed into theproximal end 18A of the pre-filled pod 12A. In a further configuration,with reference to FIG. 7, the female luer connection 14A may alsoinclude a vent 77 adapted to allow gas to escape from the captive airchamber 48A but does not allow passage of liquid therethrough. It iscontemplated herein that the use of a saline filled syringe assembly 60Acould allow the pre-filled pod 12A to evacuate air and be used on aconventional hospital pump with a liquid filled behind thetransitionable stopper 24A to advance the transitionable stopper 24A ina distal direction in accordance with pump movement.

It is contemplated herein that the pre-filled pod 12, 12A of the presentinvention is suitable for use in drug administration via an IV, dilutioninto an IV system, and through safety needles that can be attached forinjection.

Referring to FIGS. 9-10, the pre-filled pod 12 of the present inventionmay be adapted to indicate to the user that a certain amount ofsubstance 13 has been expelled by markings 90 provided on a portion ofthe pre-filled pod 12. Accordingly, the medical practitioner may observethat a complete dose corresponds to a specified amount of substance.Referring to FIG. 9, the pre-filled pod 12 is shown in the initialunused position. Referring to FIG. 10, the pre-filled pod 12 is shownhaving a portion of the substance partially expelled from the pre-filledpod 12 upon application of force to the plunger rod 78 of the syringeassembly 60. It is appreciated herein that although the pre-filled pod12 and the syringe assembly 60 are shown in the drawings in asubstantially horizontal orientation, in use, the pre-filled pod 12 andthe syringe assembly 60 will likely be employed in an angledconfiguration, such as about 60° with respect to vertical.

Referring to FIGS. 11-15, the pre-filled pod 12B may be used asdescribed above in conjunction with a regulator 100 for regulating theamount of substance 13B expelled from the pre-filled pod 12B over apredetermined period of time. In certain situations, a medicalpractitioner may be required to introduce a substance 13B, such as amedication, narcotic, and the like, into an IV system or other similartreatment delivery system over a long period of time. Some dosingdeliveries may require that a medical practitioner deliver a completedose over a period of time on the order of five minutes by manuallyadvancing a syringe plunger in incremental steps. This slow pacing canbe difficult for a hurried medical practitioner to maintain, andconsistency may be lost by human error. The regulator 100 of the presentinvention may be provided in fluid communication with the transitionablestopper 24B in order to provide for a constant expulsion of substance13B from the pre-filled pod 12B over a predetermined length of timewithout requiring a medical practitioner to determine the pacing of thedose. As shown in FIGS. 12-14, the regulator 100 coupled with thepre-filled pod 12B of FIG. 11, is shown coupled with a standard syringeassembly 60B such that fluid, such as air, within the interior chamber70 of the syringe assembly 60B is directed into the regulator 100, themechanism of which will be discussed herein.

Referring to FIGS. 12-13, in use the medical practitioner determines theappropriate amount of dose that should be provided over a specifiedperiod of time. The medical practitioner may then deploy the plunger rod78B or set an automatic plunger deployment system (not shown) to deploythe plunger rod 78B. The regulator 100 of the present invention preventsover-dosing within a specified period of time by restricting theadvancement of the transitionable stopper 24B. In certain situations, asingle deployment of the plunger rod 78B of the syringe assembly 60B maybe sufficient to properly deliver the dose of substance 13B bypressurizing the regulator 100 in a single or first cycle. In othersituations, a second cycle, shown in FIGS. 14-15, may also be required.In the second cycle, the medical practitioner re-deploys the plunger rod78B of the syringe assembly 60B. After completion of an appropriatenumber of cycles, such as after completion of the second cycle, theindicator 102, shown in FIG. 15, may be activated to indicate that theregulator 100 has sufficient pressure to deliver a complete dose over aspecified and predetermined period of time.

Referring to FIGS. 16-18, the interval setting of the regulator 100 maybe established by the medical practitioner. During use, the medicalpractitioner may set the regulator from the “off” position, shown inFIG. 16, to a metered dose position, shown in the pre-use state in FIG.17, and in the after-use or dispensed state in FIG. 18. The medicalpractitioner may align an activation trigger 108 with a correspondingindicator 110 positioned on a moveable portion 112 of the regulator 100.The corresponding indicator 110 may include indicia, such as 20 ml/hr,which indicates to the medical practitioner the appropriate setting forexpelling the substance 13B.

Referring to FIGS. 19-22, the metered dose dispensing of the regulator100 is accomplished by providing the regulator in engagement with thepre-filled pod 12B such that the regulator 100 is in fluid communicationwith the proximal end 18B of the pre-filled pod 12B. A standard syringeassembly 60B is provided in fluid engagement with a first access port120 of the regulator 100 such that the outlet opening 72B is alignedwith the first access port 120. The housing 121 of the regulator 100includes a cavity 122 aligned with the first access port 120 including atransitionable valve member 124. During operation, as shown in FIGS.19-20, the plunger rod 78B of the syringe assembly 60B is deployed, asshown in FIGS. 12-13, which directs pressurized gas into the firstaccess port 120. During the introduction of pressurized gas into thefirst access port 120, the transitionable valve member 124, such as aball check valve, is transitioned to allow passage of air into theregulator 100. After injecting all of the gas into the first access port120 of the regulator 100, the clinician may aspirate the syringeassembly 60B and re-deploy the plunger rod 78B, as shown in FIGS. 14-15.Referring to FIGS. 21-22, during aspiration, a second transitionablevalve member 130, such as a ball check valve, is transitioned to allowingress of air through a second access port 125 from the atmosphere.

Referring specifically to FIG. 20, during deployment of the plunger rod78B, the transitionable valve member 124 is deployed to allow air topass into the regulator 100 and to allow pressurization of the regulator100. Referring to FIG. 22, when pressurized air is not being directedinto the regulator 100 by deployment of the plunger rod 78B, then thetransitionable valve member 124 blocks the escape of air from theregulator 100 by sealing the pathway 123, shown in FIG. 20. Duringaspiration, as shown in FIG. 22, the second transitionable valve member130 is deployed to allow air to pass into the regulator 100 and interiorchamber of the syringe assembly 60B through pathway 129. Referring toFIG. 20, when air is not being withdrawn from atmosphere into theregulator 100, the second transitionable valve member 130 blocks theescape of air from the regulator 100 by sealing the pathway 129, shownin FIG. 22. After the regulator 100 is properly pressurized, theindicator 102, shown in FIG. 15, is activated and the medicalpractitioner may disconnect the syringe assembly 60B from the regulator100. The medical practitioner then aligns the activation trigger 108with a corresponding indicator 110 of the regulator 100, as shown inFIGS. 16-18, and the regulator 100 introduces a proper pressure to thetransitionable stopper 24B to expel the substance 13B at an appropriatedosing. The regulator 100 ensures that a proper amount of pressurizedair is applied to the transitionable stopper 24B throughout the metereddosing by suitable valve means. Optionally, the indicator 102 may beadapted to relieve pressure from within the regulator 100 in the eventthat the regulator 100 is over pressurized. As shown in FIG. 22, anundercut 103 at the base of the indicator 102 may allow air to leakbetween the indicator 102 and the surrounding housing 104 once theindicator 102 is deployed in a direction shown by arrow D of FIG. 22past a specified point. In another embodiment, a spring 107 may bedisposed within the regulator 100 between a lower end 105 of theindicator 102 and a contact surface 106 of the regulator 100 to bias theindicator 102. Once the indicator 102 is deployed against the bias ofthe spring 107, air may pass from within the regulator 100 to theatmosphere through the undercut 103 between the indicator 102 and thesurrounding housing 104. In accordance with an additional embodiment,the syringe assembly may be replaced by a finger pump, a longitudinallycollapsing bellows, or a “squeeze ball” mechanism.

In accordance with yet another embodiment, as shown in FIGS. 23-24, apre-filled pod assembly 200 and regulator 201 are shown, as describedherein, with the exception that the pre-filled pod assembly 200 includesa capsule 220 for containing a substance 202 disposed therein, such asfluid medication, sterile water, saline, fluid narcotic, or othercontrolled substance. The pre-filled pod assembly 200 may include apre-filled pod 210 having a distal end 211, a proximal end 212, and asidewall 214 extending therebetween defining an interior 216. Thecapsule 220 is disposed within the interior 216 of the pre-filled pod210 and may be held within the interior 216 in a specific orientation byat least one grommet 217, such as a rubber grommet 217. The capsule 220may include a first opening 218 adjacent a first end 221 of the capsule220 and a second opening 222 adjacent a second end 223 of the capsule220. The first opening 218 may be aligned with the proximal end 212 ofthe pre-filled pod 210 and the second opening 222 may be aligned withthe distal end 211 of the pre-filled pod 210. In a further embodiment,the pre-filled pod 210 further includes a transitionable stopper 230, asdescribed herein. The first opening 218 of the capsule 220 may bealigned such that in operation, as the transitionable stopper 230 isadvanced or moved in a downward direction, as shown in FIG. 24, air 232disposed over the capsule 220, as shown in FIG. 23, is pressurized andenters the capsule 220, as shown in FIG. 24, via the first opening 218.The pressurized air 232 entering the capsule 220 expels the substance202 from within the capsule 220 through the second opening 222 and outthe pre-filled pod assembly 200.

As shown in FIG. 24, at least a portion of the transitionable stopper230 seals the first opening 218. In one embodiment, the volume ofsubstance 202 is greater than the volume of air 232, which limitsexpulsion of the air 232 from the capsule 220 of the pre-filled pod 210.In order to ensure that air is not expelled from the capsule 220, incertain embodiments, the pre-filled pod 210 is oriented such that theregulator 201, or optional syringe assembly (not shown), is alwayshigher than the pre-filled pod 210. In another configuration, the secondopening 222 of the capsule 220 is dimensioned such that due to surfacetension forces, the substance 202 does not exit the second opening 222unless sufficient pressure is applied to the capsule 220 through thefirst opening 218. Optionally, an air bubble 240 may be providedadjacent the second opening 222 to further limit expulsion of thesubstance 202 absent applied pressure as discussed herein. As such, thesubstance 202 of the capsule 220 is isolated from the other componentsof the pre-filled pod assembly 200. In a further embodiment, lubricationof the capsule 220 is not required as the pressurized air provides themechanism for expelling the substance 202 from the capsule 220. This maybe advantageous as silicone oils conventionally used to lubricate thesyringe assembly (not shown) or regulator 201 will not enter the capsule220, thus limiting contamination of the substance 202.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. Accordingly, theparticular arrangements disclosed are meant to be illustrative only andnot limiting as to the scope of invention which is to be given the fullbreadth of the claims appended and any and all equivalents thereof.

The invention claimed is:
 1. A pre-filled pod assembly comprising: apre-filled pod having a distal end, a proximal end, and a sidewallextending therebetween defining an interior; a transitionable stopperdisposed within the interior of the pre-filled pod; and a regulatorcoupled to the proximal end of the pre-filled pod and provided in fluidcommunication with the interior of the pre-filled pod comprising: aninlet, an outlet, and a housing defining a cavity between the inlet andthe outlet: a valve that controls flow through the inlet and into thecavity; and an outlet valve that controls flow out of the cavity andthrough the outlet; wherein when the valve and the outlet valve are bothin a closed position, the cavity is sealed, and when the valve is in anopen condition, pressurized gas or fluid may enter the cavity, and whenthe outlet valve is in an open position, pressurized gas or fluid storedin the cavity may pass through the outlet, and wherein the outlet of theregulator is in fluid communication with the interior of the pod suchthat pressurized gas or fluid flowing from the outlet of the regulatorenters the interior of the pod advancing the transitionable stopper froman initial position to an activated position in which at least a portionof a fluid contained within the interior of the pre-filled pod isadvanced therefrom.
 2. The pre-filled pod assembly of claim 1, whereinthe outlet valve supplies pressurized gas or fluid to the transitionablestopper in a predetermined amount.
 3. The pre-filled pod assembly ofclaim 1, further comprising a standard syringe in fluid communicationwith the inlet of the regulator, such that depression of a plunger rodof the standard syringe opens the valve and forces pressurized gas intothe cavity of the regulator.
 4. The pre-filled pod assembly of claim 3,further comprising a second valve controlling flow from an air or fluidsource into the inlet, wherein aspiration of the syringe opens thesecond valve allowing air or fluid to enter the syringe.
 5. Thepre-filled pod assembly of claim 4, wherein the air or fluid source isthe atmosphere surrounding the regulator.
 6. The pre-filled pod assemblyof claim 4, wherein repeated depression and aspiration of the syringewhen the outlet valve is closed causes pressure to build in the cavity.7. The pre-filled pod assembly of claim 1, wherein the regulator furthercomprises an indicator that is activated when a pressure of pressurizedgas or fluid stored in the cavity is sufficient to advance the desiredamount of liquid from the interior of the pod.
 8. The pre-filled podassembly of claim 1, wherein the regulator comprises an activationtrigger configured to be aligned with an indicator for allowing a userto open the outlet valve and set the flow through the outlet valve toadvance the liquid at a metered rate.
 9. The pre-filled pod assembly ofclaim 1, wherein introduction of pressurized gas or fluid into the inletbuilds pressure in the cavity when the outlet valve is closed andclosing the inlet valve causes the pressurized gas or fluid in thecavity to be stored in a pressurized state.
 10. The pre-filled podassembly of claim 1, wherein the cavity has a fixed volume.